E-D0774001-00-00 1

SATAKE INSTRUCTION MANUAL

PADDY HUSKER WITH ASPIRATOR

HU10FH(2)-T, HA10W(3)-T

WARNING

• Do not carry out any operation, maintenance or inspection of the machine until you have read and well understood the contents of this instruction manual.

• Keep this manual at hand whenever any operation, maintenance or inspection of the machine is being carried out.

SATAKE (THAILAND) CO., LTD.

2

CONTENT

1. LIMITED WARRANTY................................................................................................................. 3

2. SAFETY...................................................................................................................................... 4

2.1 Warning / Caution Types and Meanings ....................................................................... 5

2.2 General Instructions ...................................................................................................... 6

2.3 Special Precautions....................................................................................................... 8

2.4 Warning Stickers ........................................................................................................... 9

2.5 Location of Warning Stickers....................................................................................... 10

3. SPECIFICATIONS .................................................................................................................... 13

4. DIMENSIONS........................................................................................................................... 15

5. CONSTRUCTION..................................................................................................................... 16

6. INSTALLATION ........................................................................................................................ 17

7. WIRING AND AIR PIPING........................................................................................................ 30

8. CONTROL BOX ....................................................................................................................... 31

8.1 Names and Function of Terminal Base in Control Box. ............................................... 31

8.2 Names and Function of Each Part of Control Box. ...................................................... 32

9. AUTOMATIC OPERATION FLOWCHART ................................................................................ 37

10. PREPARATION FOR OPERATION ......................................................................................... 38

11. OPERATION........................................................................................................................... 44

12. MAINTENANCE AND INSPECTION....................................................................................... 48

13. TROUBLESHOOTING............................................................................................................ 64

14. CONSUMABLE PARTS LIST .................................................................................................. 67

EMERGENCY ADDRESS AND TELEPHONE ............................................................................... 68

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1. LIMITED WARRANTY

The machine was produced under quality control and inspection. But, if there are any problems under normal use the limited warranty for the machine extends for the first year beginning on the date of purchase of the machine.

1. Please contact our agency or sales office to repair. If there is a problem within limited warranty period, We will repair for free (only under normal use condition). After the warranty period, repair fee would be billed.

2. It will be charged during limited warranty period following conditions. (1) Damages & losses misuse of improper or operated installation with no care. (2) Damages & losses unauthorized modification or unauthorized repair. (3) Damages & losses because of disasters (fire, flood, storm and earthquake

etc.), pollution, unusual voltage & damaged by sea air(rust). (4) Damages & losses which you moved or dropped the machine after setting. (5) Damages & losses which use of unauthorized spare parts or repair at

unauthorized agency or factory. 3. We will supply parts of the machine for 7 years after stop of production. But within

this period some special parts are exceptional. 4. Basically, We will stop to supply parts in 7 years after discontinued to produce. But if

you have a request to order the parts, We will discuss about it. All warranty informations, machine features and specifications are subject to change without notice.

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2. SAFETY

WARNING Do not carry out any operation, maintenance or inspection until you have read and well understood the contents of this instruction manual.

• Keep this manual at hand for reference whenever any operation, maintenance or inspection of the machine is being carried out.

• When you operate, maintain or inspect the machine, you are requested to follow instructions and warnings as stipulated in this manual. If you have any questions or indistinct points, you should suspend operation of the machine or your work until you can clarify it with the Satake office listed at the end of this manual for inquiries about the machine.

• Satake shall not be responsible for any injury, loss or damage caused by failure to observe instructions stipulated in this manual, by misuse or modification without our permission.

This chapter describes the definition of hazard signal words as well as safety precautions to be observed at the time of operation, maintenance or inspection as detailed and classified in the “General Inspections” and “ Special Precautions.”

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2.1 Warning / Caution Types and Meanings Hazard warning in this instruction manual and warning stickers attached on the machine main body are classified into the following three kinds, depending on the degree of risk of accident. Operator must recognize the importance of the warnings, and carefully follow the instructions given in this manual.

This shows potential hazard. If you do not follow this, WARNING there is some possibility of fatal or serious injury.

This shows potential hazard. If you do not follow this,

there is some possibility of middle or minor class CAUTION injury, damages of the equipment / machinery or

misconduct in material or product.

This is used for calling special attention to or NOTE adding emphasis to a certain information required

to be noticed.

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2.2 General Instructions

WARNING • The operator is supposed to pay attention to the following points to

ensure safety in operating, inspecting and serving the machine.

(1) Operator must contain long hair in a hair cover and neatly wear clothes and shoes

that are suitable for work. When carrying out any inspection or maintenance, wear appropriate protective gear such as helmet and safety shoes.

(2) Keep clean the surroundings and passages around the machine. (3) Do not pour water over the machine. Water in the machine shorts the electric

circuits, consequently causing the machine to break down. (4) Do not fail to ground the machine in order to protect a person from being involved in

electric accidents and to prevent fires from occurring due to current leaks. (5) Never touch the live parts inside the machine after turning on power. (6) Do not permit any person who has not been properly trained to operate or service

the machine. (7) Keep out any person other than those permitted by the operator. Never let children

come close to the machine. (8) Do not fail to inspect the machine before starting operation. When carrying out any

inspection work, always power off and clearly indicate that the machine is under inspection or maintenance both in the control room and control panel at the work shop.

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(9) Always power off before inspection and maintenance and follow the appropriate lock out procedure. After the inspection, make sure that there are no tools left.

(10) Check for any looseness or damage on bolts, nuts and belts. Make sure to restore the cover after the checking.

(11) Check for any damages on power cords and wire cables. Also, check for any looseness or disconnection of connectors and plugs.

(12) Operate the machine with all covers attached. Do not attempt to remove any cover during the machine operation.

(13) Always stop the machine before greasing the driving part of the machine. (14) Operator should well understand the power off procedure for a case of emergency. (15) When working with two or more persons, each person must confirm communication

with others before starting work.

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2.3 Special Precautions (1) Install the machine in a level and stable place. Unleveled and unstable installation

will cause vibration and poor performance of the machine. (2) Do not operate, inspect or maintain the machine with any part that is not specified in

this instruction manual. (3) Keep sufficient working space around the machine. (4) Before turning the power on, confirm the safety of the surroundings and passages

around the machine. (5) Handle the machine with care. Careless handling of the machine may lead to

malfunction and failure of the machine. (6) Keep alert to the machine, If any abnormality is found, stop the operation and check

the machine to ensure safe operation. (7) When using a ladder, it must be set in stable location. (8) In case the machine is used in a dusty place, wear a dust-proof mask and goggles. (9) If employees of a plant are unable to read or write, the owner of the plant must

explicitly draw their attention to any existing hazards and must give them special instruction.

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2.4 Warning Stickers

! NOTE How to handle Warning Stickers

• Check if letters and illustration on the sticker are legible and if not, remove dirt on the sticker or replace it.

• Use cloth, water or cleanser to remove dirt. Do not use organic solvent or gasoline.

• In case the sticker is damaged, lost, or illegible, replace it with a new one.

This machine is provided with warning stickers on certain locations where a special precaution is required. It is important for operators to know the location and contents of each stickers and follow the instruction on the sticker to prevent accidents.

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2.5 Location of Warning Stickers

Fig. 2-1 Location of Warning Stickers (1)

220283504

T070154

299001542

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Fig. 2-2 Location of Warning Stickers (2)

T070190

T019360 T037212

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Fig. 2-3 Location of Warning Stickers (3)

T037212 T037212

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3. SPECIFICATIONS

Model HU10FH-T(2)-T + HA10W(3)-T

For Basmati rice

Parboil rice 3.5-4.0 tons / hour (Paddy) Process Capacity (Husking ratio 90%)

Basmati Non parboil rice 2.5-3.0 tons / hour (Paddy)

Power required Husker HU10FH(2)-T + Aspirator HA10W(3)-T 7.5 kW – 6P, 52 kW + 3.7 kW – 4P, 0.1 kW

Main Shaft Speed Fan Shaft Speed

Husker Aspirator

: HU10FH(2)-T : HA10W(3)-T

1150 rpm 1400 rpm

Coil spring (HU) Ø8 mm. (Blue)

Size Diameter : 10 inch ,Width : 10 inch Robber roll

Hardness 87° ± 5°

Net weight Husker Aspirator

: HU10FH(2)-T : HA10W(3)-T

588 kg 588 kg

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For long grain (except Basmati rice)

Process Capacity (Husking ratio 90%)

Long grain (except Basmati rice) 5.0 ~ 6.0 tons / hour (Paddy)

Power required Husker HU10FH(2)-T + Aspirator HA10W(3)-T 7.5 kW – 6P, 52 kW + 3.7 kW – 4P, 0.1 kW

Main Shaft Speed Fan Shaft Speed

Husker Aspirator

: HU10FH(2)-T : HA10W(3)-T

1100 rpm 1400 rpm

Coil spring (HA) Ø10 mm. (Black)

Size Diameter : 10 inch ,Width : 10 inch Robber roll

Hardness 87° ± 5°

Net weight Husker Aspirator

: HU10FH(2)-T : HA10W(3)-T

588 kg 588 kg

NOTE

• Husking ratio depends on material quality and impurity high impurity material. May cause malfunction of machine.

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4. DIMENSIONS

Fig. 4-1 Dimensional Drawings

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DOWNUP

CHUTE

Sensor

TankShutter

Valve

Chute

Adjusting bolt

Control box

Valve DValve E

Screw Conveyor

Feeder

Rubber roll

Screw Conveyor

Husk outletValve CHusked rice outlet

Screw conveyor

Valve AValve B

5. CONSTRUCTION

Fig. 5-1

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6. INSTALLATION

6.1 Rigging Method of the Machine

WARNING • Use a wire having sufficient strength.

• Remove the safety cover for making work space during installation of husker

(fix the machine with body of aspirator).

• Use great care not to damage the body etc. when carrying and rigging work.

Fig. 6-1

Remove safety cover

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6.2 Confirmation of Levelness

CAUTION • If the machine is not set horizontally it may not be able to exhibit expected

capacity fully.

• Ensure the levelness of the machine and bolt it securely to the floor. Set the machine at the specified position and make sure that it is placed horizontal.

Fig. 6-2 Then bolt the machine securely with the bolts. 6.3 Position setting.

Fig. 6-3

Set Levelness

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COVER

6.4 Selection of Floor The Floor to be selected for installation must have enough strength. 6.5 When install the machine, Allow enough space around the machine for inspection jobs or passage as show in Fig. 6-4

Fig. 6-4 6.6 Process of Installation Comply with the following procedure to assemble the machine.

(1) Remove the top cover

Fig. 6-5 Assembly procedure (1)

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Angle

(2) Fit the husker onto the aspirator. Fix the bolts.

Fig. 6-6 Assembly procedure (2) (3) Remove the angle and fit the bolt on the body.

Fig. 6-7 Assembly procedure (3)

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(4) Attach the Top Covers.

Fig. 6-8 Assembly procedure (4) (5) Attach motors to the husker and the aspirator. (6) Fit timing belt to husker and V-belt to aspirator.

WARNING

• Caution must be exercised to prevent your fingers from being pinched at the pulley and belt.

CAUTION

• Securely fit the motor pulley.

• Fit the belts in accordance with Fig. 6-9, and sure to adjust the belt alignment.

TOP COVER

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V-belt (50Hz)B-68 2 Pcs.(60Hz)B-66 2 Pcs.

Dividing screw

directionRotation

Husk screw pulley

Motor pulleyMotor 3.7kW-4P

Fan shaft pulley

Tension Pulley

Timing belt600DS8M2304

directionRotation

Geared motor 0.1kW

Mixed grain screw pulley

V Belt A-62

V-belt A-47

Motor7.5kW-4PMotor pulley

Movable shaft pulley

Main shaft pulley

V-belt (50Hz)B-67 (High RPM) 2 Pcs.(60Hz)B-65 (High RPM) 2 Pcs.

Fig. 6-9 Belt Routing and Belt Sizes (7) Dust – Suction piping

Note the following points when installing the dust – suction piping. 1) Intake airflow of 3 m3 /min. is required. 2) Number of bends as well as the piping lengths should be minimized with the dust – --removing 3) Put the dumper for adjusting air – volume of each machine.

Dust direction

Dust direction

Fig. 6-10

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(8) Adjust the tension of belts and be sure to fit safety covers.

CAUTION • Once the tension has been adjusted, be sure to fit safety covers.

• Be careful to avoid any excessive belt tension. Securely fit the motor pulley. Adjust the tension of belts so that they deflect 10-20 mm when pressed at the center. (9) Piping of mixed grain outlet.

Set the piping angle from the previous process to husker at 60° or more. If the piping angle is less than 60°, it causes the decrease of capacity due to bad paddy flow. Maximum input capacity is depends on variety of material etc,. may need to adjust angle of piping.

Fig. 6-11 Sketch of the piping (1)

From previous process

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Set the piping angle from husked rice outlet to the subsequent process at 40° or more.

(10) Control air piping Route the air piping to the coupler under the control set supply air pressure to the coupler about 0.5 MPa.

To Paddy Separator Fig. 6-11 Sketch of the piping (2)

Fig. 6-12 Sketch of the piping (3)

Control box

Compressed air supply

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(11) Electric Wiring

WARNING • Ensure that the main power is turned OFF when connecting any wiring work.

CAUTION • Make sure to close the cover of the control box after the wiring work.

• If the cover of the control box is forgotten to close, the electronic parts may damage by dust.

• Fit the elector – magnetic breaker for each motor.

• Make the electric wiring to stop the paddy supply in case that the distribution motor stops by the overload for some reason.

(1) Must use protective device such as contact breaker, electromagnetic contactor or thermal relay to each motor. Suggested thermal capacity is as rated in the table below. Confirm amperage with the name plate of motor and set the thermal relay capacity.

Table 6-1, 6-2 and 6-3 - Motor of paddy husker. Table 6-4 - Motor of paddy aspirator. Table 6-5 - Geared motor of paddy aspirator.

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Motor Specification

Voltare Frequency Amperage

(V) (Hz) (A)

Thermal Relay

Capacity (A)

200 50 29.0 29.0

200 60 28.0 28.0

380 50 15.0 15.0

440 60 13.0 13.0

460 60 12.7 12.7

Table 6-1 - 7.5kW, 4P motor (TH1)

Motor Specification

Voltare Frequency Amperage

(V) (Hz) (A)

Thermal Relay

Capacity (A)

200 50 33.0 33.0

200 60 30.0 30.0

380 50 17.0 17.0

440 60 14.5 14.5

460 60 14.5 14.5

Table 6-2 - 7.5kW, 6P motor (TH1) (for HU10FH model only)

Motor Specification

Voltare Frequency Amperage

(V) (Hz) (A)

Thermal Relay

Capacity (A)

200 50 45.0 45.0

200 60 42.0 42.5

380 50 22.5 22.5

440 60 19.5 19.5

460 60 19.0 19.0

Table 6-3 - 11kW, 4P motor (TH1)

Motor Specification

Voltare Frequency Amperage

(V) (Hz) (A)

Thermal Relay

Capacity (A)

200 50 15.0 15.0

200 60 14.2 14.2

380 50 7.7 7.7

440 60 7.1 7.1

460 60 6.8 6.8

Table 6-4 - 3.7kW, 4P motor (TH2)

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Motor Specification

Voltare Frequency Amperage

(V) (Hz) (A)

Thermal Relay

Capacity (A)

200 50 29.0 29.0

200 60 28.0 28.0

380 50 15.0 15.0

440 60 13.0 13.0

460 60 12.7 12.7

Table 6-6 - 0.1kW (TH3)

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TH2

MC2 MC3

TH3 TH1

MC1

K k

TH1TH2TH3

MC3

MC3

MC2

MC2

MC1

MC1PB3 PB2 PB1

PB1PB2PB3

PB

FUSEPL

LIS PS HRSV

IN2IN1 SWU V

CR2 CR3

CR1DRY1 CR4

*Local wiring (Refer to next pape)

NFB(non-fuse circuit breaker) if the power source is any voltageother than 200 V,make it to 200 V

Electro-magnetic contactor

Thermal relay

L l

CurrenttransformerAmmeter

Single phaseAC 200V

(Control box)

(Control box) Emergency stop

Stop Stop Stop

Run Run Run

Fig. 6-13 Wiring Instructions <On – site wiring>

• In case that the husker is not engaged with paddy separator. (1) Remove the jump wire between the terminal No.8 and No.9. (2) Connect the auxiliary terminal of thermal relay of the distribution motor with the terminal No. 8 and No.9.

E-D0771018-00 29

Fig. 6-14 Terminal Base of Control Box (One Part)

• In case that the husker is engaged with paddy separator:

(1) Remove the jump wire between the terminal No. 8 and No. 9 (2) Connect the auxiliary terminal of the thermal relay of the distribution motor with the external sensor in series and then connect them with the terminal No.8 and No. 9.

Fig. 6-15 Terminal Base of Control Box (One Part)

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7. WIRING AND AIR PIPING

WARNING • Ensure that the main power is turned OFF when performing any wiring work.

CAUTION • Make sure to close the cover of the control box after the wiring work.

• If the cover of the control box is forgotten to close, the electronic parts may damage by dust.

SensorBall valve

Air cylinder (shutter)

Air cylinder (roll)Control

box

(out)

(in)

Actuator valve

Air (outlet)

Regulator (for roll pressure)

Air (outlet)

valve

Regulator

Filter

Compressed Air(inlet)

(for regulating the control pressure)

pressure gauge

CR1

CR3

HR

FUSEIN1 IN2

PL SW

LIS

DRY1

CR2

PS SV

CR4

PE

Externalsensor

Feeder controller

Singlephase Earthlamp switchSelector Fuse

Hour meter

Solenoid

Speedcontroller

(out)

controller(in)

Speed

Fig. 7-1 Wiring Instructions

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CR1

CR3

HR

FUSEIN1 IN2

PL SW

LIS

DRY1

CR2

PS SV

VU

CR4

P2P1

PE

Externalsensor

AC200V EarthPilotlamp switch

Selector Fuse

Hour meter

Electromagnetic valveSensor

Feeder externalsignal

(Jump wire)

for feederPower

8. CONTROL BOX

8.1 Names and Function of Terminal Base in Control Box.

Fig. 8-1

Fig. 8-2 Control Box (Side View)

Hour meter Timer relay

Relay

Socket Changeover switch

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8.2 Names and Function of Each Part of Control Box.

Fig. 8-3 Control Box (Front View)

CAUTION • Make sure to close the cover of the control box after the wiring work.

• If the cover of the control box is forgotten to close, the electronic parts may damage by dust. • TP (Terminal Pin)

UV: Input power source AC 200V single phase

PE: Earth

LIS: HU tank paddy detection sensor

SV: Power of electro-magnetic valve

PS: For external sensor (PS)

Fuse (2A) Changeover switch

Hour meter

Feeder controller

Pilot lamp

E-D0771022-00 33

IN, IN 2: Power of feeder controller

E: Earth of feeder controller

P1, P2: External signal of feeder controller (Run, Stop signal)

• Timer relay --Set the waiting time from the detection of sensor to the start of husking. – Set range: 0~60 sec. (At factor shipment: 20 sec)

• Hour meter --Display the accumulated husking hour. (with zero setting function)

• Power lamp -- Light on when the power is ON. (AC 200V single phase)

• Fuse (2A) -- For protection of operation circuit.

• HAND/AUTO changeover switch - HAND: To open the supply valve, operate the feeder and pressurize the rolls. - STOP: To close the supply valve, stop the feeder and release the rolls. - AUTO: To perform the automatic operation by a sensor for the control. Automatic ----------- sequence to open the supply valve, operate the feeder, and pressurize the rolls or -------------- in reverse to close the supply valve, stop the feeder and release the rolls.

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8.3 Names and Function of Each Parts of Feeder Controller.

Fig. 8-4

Display lamp (RUN)

Display lamp (TRIP)

Frequency adjusting volume (FREQ)

Amplitude adjusting volume (V)

Second amplitude adjusting volume (V2)

Machine screw

Power switch

Machine screw

FRONT

Fuse holder

Power / voltage changeover switch

Input terminal base

Output terminal base

Terminal base for external input signal

External volume connection switch

INSIDE OF FRONT

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Fig. 8-5 Names of Each parts of Feeder Controller

• Display lamp (RUN)

- To light on during operation only. • Display lamp (TRIP)

- To light on and stop the output when the protection of over-voltage and over - current is functioned.

• Frequency adjusting volume (FREQ) - To use at the adjusting work of frequency.

• Amplitude adjusting volume (V) - To adjust the flow rate of paddy.

• Second amplitude adjusting volume (V2) - Not available.

BOTTOM

Grommet of output cable

Grommet of input cable

Grommet for external signal cable

Output connector for output frequency displayer

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• Power switch To turn ON and OFF the feeder.

• Terminal base for external input signal To connect the external input wire.

• Connecting switch of external volume Not available.

• Power / Voltage changeover switch To set AC 200V. (At factory shipment: AC 200V)

• Fuse holder To protect the feeder controller circuit.

• Input terminal base The power source for feeder controller.

• Output terminal base The power source for electro-magnetic coil of feeder.

• Grommet for external signal cable To pass the external signal cable.

• Output connector for output frequency displayer To connect the cable of a tachometer.

• Grommet for output cable To pass the output cable.

• Grommet for input cable To pass the input cable.

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START

Start operation of HU,HA and distribution motors.

Control boxSet the manual / auto switch at AUTO.

Any paddy in the HU hopper?Wait NO

Wait Is the PS hopper empty?Yes

HU hopper : empty ? PS hopper : full ? NONO

YES YES

Close the shutter and release the rolls. Close the shutter and release the rolls.

PS hopper : full ?YES

NO

YES

NO

Open the shutter and pressurize the rolls.

9. AUTOMATIC OPERATION FLOWCHART

Fig. 9-1 Automatic Operation Flowchart

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Tension bolt for

Motor 7.5kW

Motor 3.7kW

motorTension bolt for

belt

V-belt tension

Air pressure 0.5MPa or moreGear motor

10. PREPARATION FOR OPERATION

WARNING • Ensure that the main power is turned OFF when conducing any inspection

or maintenance work.

• After completion of inspections, be sure to fit safety covers back in space. 1. Check and adjust the following items (see Fig. 10-1) (1) Are the centers of pulley aligned ? (2) Any loosened pulley set bolts ? (3) Is the tension of belt correct ? (4) Is the control air pressure 0.5 MPa or more ? (5) Is the air pressure for rubber roll 0.2 MPa ?

Fig. 10-1

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CAUTION • Adjust air pressure at 0.2 MPa (for rubber roll)

• May occurred % of broken and cracked rice is increased even adjust rubber roll air pressure at 0.2 MPa need to check output.

• Adjust proper rubber roll air pressure (depends on material). Adjustment of rubber roll air pressure

a) Pull the handle of regulator.

b) Turn the handle and adjust air pressure. Clockwise – increase, Counter – clockwise - decrease

Fig. 10-2 Control box (front) and regulator

Regulator

Rubber roll air pressure

Supplied air pressure

Emergency stop switch Change over switch

Feeder Controller Pull the handle of regulator

then adjust air pressure.

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(2) Run the motor of the machine to check the direction of rotation and to check for any unusual noise or odor. After the check is over, stop the motor of the machine.

WARNING • When checking the direction of rotation, ensure that no one is present around the

adjustment. Be carefull not to touch the driving section.

• If any fault occurs, immediately shut off the power supply to stop driving the machine.

CAUTION • If the direction of rotation is wrong, machine performance will not be fully drawn, and

faults may result. Check the direction of rotation before starting any husking operations

• When operating without load, be sure to supply air, and ensure that the rolls are not mutually in contact.

Fig. 10-3 Rotation direction

E-D0775021-00 41

(3) Once the inspections complete, be sure to attach all safety covers. (4) Energize the control box to check the functions of machine components.

NOTE • Check the machine motor without running it.

• Keep the paddy hopper unload when conducting any check. [HAND] (1) Position the change over switch to “HAND”. (See Fig. 10-2) - Paddy feed valve will open. (See Fig. 10-2) - Feeder will vibrate. - Rubber rolls will be pressurized (brought into contact). (2) Restore the change over switch. - Paddy feed valve will close. - Feeder will stop. - Rubber rolls will be released (separated).

Fig. 10-4 Husker

Sensor

Feed valve

Manual Shutter

Feeder

Movable shaft

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[AUTO] Check following items when no paddy in the tank. (1) Position the change over switch at “AUTO”. (See Fig. 10-2) sensor detects no paddy in the

HU tank (LED stays ON). The machine does not act at all. (Since there is no paddy, the machine does not work after passing the setting time (at factory setting : 20 sec.) of a timer in the control box. Check the light out of LED by touching the tip of a sensor. At this state, wait till the setting time (at the factory shipment : 20 sec.) of a timer in the control box. - Paddy feed will vibrate. - Rubber rolls will be pressurized (brought into contact).

(2) Restore the change over switch to “STOP” (See Fig. 10-2) - Feeder will stop - Rubber rolls will be released (separate). Position setting

• Change – over switch : STOP

• Amplitude adjusting volume : 70

• Valve A : Middle

• Valve B : Middle

• Valve C : 2nd scale line from right

• Valve D : Middle

• Valve E :For long grain ->open, short grain -> close

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Valve C

Valve D

Feed valve

Valve BValve A

Amplitude adjustingvolume

Change over switch

CAUTION • Operate over the rated capacity may cause failure of the machine.

Fig. 10-5

Valve E

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11. OPERATION

NOTE • Trial run must be executed before operation.

11.1 Manual Operation (trial run) (1) Open the manual shutter then input paddy in the tank. (2) Confirm suction air in the suction pipe. (3) Turn power ON. (4) Run the machine motor. (5) Set at “HAND” the change over switch on the control box. (See Fig. 10-2)

(6) Adjust the roll pressure to set husking ratio at about 90% (See 10. PREPARATION FOR OPERATION “Adjustment of rubber roll air pressure”). Turn the knob clockwise increase. Counter – clockwise decrease.

(7) Adjust distribution by valve D and E. (8) Adjust wind sorting section by valve A, B and C.

NOTE • If the tank of paddy separator is full, set change over switch at

“STOP” (If the switch is set at “HAND”, the shutter will not be linked with the paddy separator hopper).

E-D0771034-00 45

11.2 Automatic Operation (1) Open the manual shutter then input paddy in the tank. (2) Confirm suction air in the suction pipe. (3) Turn power ON. (4) Run the machine motor. (5) Set at “AUTO” the change over switch on the control box (See Fig. 10-2). (6) Once the feed valve opens and feeder vibrates to start husking, adjust the roll - pressure to set the husking ratio at about 90%. (See 9. PREPARATION FOR - OPERATION, Adjustment of rubber roll air pressure) Turning the handle of - regulator clockwise to increase pressure (increase the husking ratio) and turning - it counter clockwise to decreases the pressure (decreases the husking ratio). (7) When the paddy sorting machine hopper becomes full. Feed valve will close, - and the roll gap will widen then will stop husking (only when it is linked with the - paddy separator hopper.) (8) Then, when the paddy separator hopper becomes empty, feed valve will open - after a timer of the timer setting to resume husking operation. (9) When the husker hopper becomes empty, feed valve will close, and the roll gap - widen to stop husking. (10) When any paddy comes, feed valve open after a time of the timer setting to - resume The husking operation.

NOTE • Adjust the feed rate of the husker to keep the fed valve open at

least 10 min. by amplitude adjusting volume at feeder controller. Need to observe the change in the husking ratio if the amplitude adjusting volume has been adjusted.

(11) Adjust the distribution by valve D and E. (12) Adjust the wind separation by valve A, B and C.

E-D0771035-00 46

11.3 Adjustment of open and closing speed of movable shaft and feed valve. (1) Adjustment of open and closing speed of movable shaft.

(2) Turn the adjusting screw to adjust open and closing speed of movable shaft. (set at 2 seconds and check it during operation). Turn the adjusting screw clockwise to slow down the air cylinder motion with the resultant increase tin the time from the feed valve opening to the moment the movable shaft roll touches the main shaft roll. On the contrary, if it takes too much time for the motion to start, turn the adjusting screw counter – clockwise.

(3) Once the adjustment completes, fix the adjusting screw using the lock nut.

Fig. 11-1 Adjusting the Speed controller

Speed controller (IN) – control air speed for closing rubber roll. Speed controller (OUT) – control air speed for opening rubber roll.

Adjusting screw

Speed controller

Lock nut

Decreaseair speed air speed

Adjusting screw

Increase

E-D0775023-00 47

Fig. 11-2 Speed Controller for Movable Shaft Opening / Closing

(2) Adjustment of open and closing speed of feed valve.

1) Loosen the lock nut of speed controller. 2) Turn the adjusting screw to adjust open and closing speed of feed valve.

Turn the adjusting screw – feed valve movement is slower. Turn it counter – clock wise feed valve movement is faster.

3) Once the adjustment completes, fix the adjusting screw using the lock nut.

Speed Controller (OUT)

Speed Controller (IN)

E-D0702031-00 48

12. MAINTENANCE AND INSPECTION

WARNING • Turn OFF the main power before conducting any cleaning or inspections of

machine components. Post a sign “UNDER INSPECTION” at the point of power shut-off.

CAUTION • If the machine is help stopped for a long time, insert may built nests at various

corner. When restarting operation, check the machine for any nests of insect, and remove them if any.

• If any parts are worm or broken, or when the times has come to replace any consumable parts, contact the nearest sales office.

•

The use of rubber roll of poor quality, such as higher hardness, brittle rubber and larger fixing hole diameter, may cause the increase of broken rice and the damage of the bearing section.

Conduct the inspections and maintenance work on a regular basis (see the following).

The inspections and maintenance are also required when keeping the machine without being operated for a long time, or when restarting operation after a long time.

(1) Occasionally check the tension of transmission V-belts, hex.belts and scooped belts of the elevator, and adjust if it is necessary.

• Pay attention to the tension particularly after installation or replacement of the belts since the elongation will be large.

E-D0771037-00 49

(2) See through the access hole of the aspirator to check for straw or any other obstacles that may hamper the paddy flow. (3) If the thickness of the main shaft rubber roll of the husker has decreased to about the half of that the movable shaft rubber roll, replace both main and movable shaft rubber rolls.

※ Confirm whether the chute position is proper, when the rubber rolls replace into new ones.

Fig. 12-1

(4) Over a long period of use, the sorting plate may collect scum as from brown rice. Wash and clean it from time to time. (5) Use the rubber roll of less than 87C (chore) ± 5C (chore) hardness. Maximum hardness of the rubber roll shall be 92 degrees or less. (6) The fixing hole diameter of retainer of rubber roll is 116 mm. Don’t use the rubber roll over the allowance of diameter (0 ~ +0.1 mm).

Fig. 12-2

Movable shaft rubber rollMain shaft rubber roll

1/2t

E-D0702033-00 50

(7) Do not use the eccentric rubber roll and low quality rubber roll.

WARNING • If the following rubber roll is used, it may happen that the broken rice ratio

increases, the husking ratio decreases or the machine is damaged.

• Excess hardness than the specified one.

• The hole diameter of retainer is over the allowance range ( 0 ~ 0.1 mm.)

• Eccentric rubber roll.

• Low quality rubber material.

E-D0702034-00 51

(8) Selection of (M10) fixing bolt to join Rubber roll and Retainer 2-2022-0050 for various size of Rubber roll.

CAUTION • Minimum clearance C shall be more than 1 mm. If not follow this, the fixing

bolt may touch against the bearing cover during operation. It will cause to damage bearing cover, bearings and shaft (Movable and Main shaft).

• Whenever install fixing bolt, do not forget to install plain washer and spring washer.

A Size (mm) B Size (mm) Remark

3.2 ~ 7.99 20 M10x20

8 ~ 12.99 25 M10x25

13 ~17.99 30 M10x30

18 ~ 22 35 M10x35

Fig. 12-3

Fig. 12-4

Rubber roll

Retainer Bearing cover

Ball bearing 6309DDUA

CC

D

Detail D

Rubber rollM10 Fixing bolt

APlain Washer and Spring washer

= 2 ~ 5 mm.B

E-D0775024-00 52

(9) Adjusting of plate

CAUTION • Never fail to adjust the clearance between plate and rubber roll to avoid

accident whenever rubber rolls are replaced. It may cause the trouble of the burning of rubber roll or the coming off plate when the machine is operated in a contacted condition of palate and rubber roll.

1) After replacement of rubber rolls, loosen the lock nut at the front cover by turning it counterclockwise and fasten the adjusting nut by 3 turnings clockwise. At this time, keep the front cover open. 2) Close the front cover securely by fastening the knob. 3) Loosen the adjusting nut until plate and rubber roll contact. After contacted fasten the adjusting nut by one turning clockwise. 4) Lock the adjusting nut by fastening the lock nut.

CAUTION • It may cause the trouble of the burning of rubber roll or the coming off of

plate when the machine is operated in a contacted condition of plate and rubber roll.

Rubber roll

Adjusting nut

Knob

Front cover

Adjusting nutLock nut

Lock nut

Front cover

1 ~ 2 mmClearance

Plate

Fig. 12.5

E-D0772025-00 53

Window BHandle

Chute

(Limit area of rubber roll)

Movable rubber rollMain rubber roll

BlueYellowRed

BlueYellow

Red

Sticker (B)Chute

Thickness:T

Window A

Sticker (A)

(10) Adjustment of chute

NOTE • For maintaining the performance of machine, conduct the adjustment of chute

depending on the wearing (remaining thickness of rubber) of rubber roll.

Fig. 12-6 Front View of Husker

1) Check rubber roll thickness of main shaft side through inspection window A whether it is at red, yellow or blue of sticker (a).

Fig. 12-7 Inspection Window A

E-D0771040-02 54

Chute

Thickness:T

Yellow

Red

Window B

Sticker (B)Blue

2) Change the chute inclination by turning handle so that chute position sets on the - same color of step though in section window B.

Fig. 12-8 Inspection Window B 3) Gradually, main shaft rubber roll turns the position of yellow and red by wearing (see

window A). Confirm the chute’s inclination also follow the color at window B. - (Chute’s in inclination links wearing of rubber rolls).

(11) Grease Supply

NOTE • Turn off the main power before pouring grease into machine.

Pour grease into the fulcrum of cylindrical bearing of movable shaft every 150 hrs. These are two pouring places of grease at the operation side and the driven side of machine.

Brand / Model : Shell / Retinax EPX2 (Contains Molybdenum Di Sulphite, lead and Soduim Nitrite fee)

Also pour grease into bearing of each shaft every 300 hrs. Use SATAKE genuine grease.

Brand / Model : Trane / Super H.P. Multipurpose grease

E-D0775026-00 55

CAUTION • The SATAKE genuine grease is used when the machine is

shipped from the factory.

• Don’t mix the different brand grease to avoid deterioration of the quality of grease.

Operation side : Pour genuine grease after removing bearing cover.

CAUTION • No pour of grease may cause the failure of machine like the

wearing of bearing and occurrence of vibration.

• Pour genuine grease sufficiently till the grease comes out from the clearance.

Fig. 12-9 Grease nipple (1) Bearing cover

Gylindrical bearing

Cover

Grease nipple

Grease nipple

Grease nipple

E-D0775027-00 56

Fig. 12-10 Grease nipple

Driven side : Pour grease after removing safety cover. (12) Discharge of drain

CAUTION • Turn off the power prior to the discharge of the drain.

• Be careful the compressed air does not exceed 0.95 MPa (9.5 kgf / m2) because the air control unit may break.

• Discharge the drain before it will reach at the baffle plate of air filter. If you fail to discharge the drain, the machine may cause the breakage.

The air control unit is necessary to remove the dust and water in the compressed air and to keep the smooth movement of an air cylinder and a solenoid valve. The drain must be discharged before it will reach at the maximum line i.e. the baffle plate in the air filter. The discharge of drain is done to push up the lower tub of air filter as below figure.

Grease nipple Grease nipple

E-D0775028-00 57

(13) Cleaning of louver Periodically (once a week) check the louver (wind drum) of the aspirator for any accumulation of dust, paddy or rice grains. Any accumulation of dust, paddy or rice grains on the louver will increase contamination of paddy in the husked rice worsen the wind – sorting results.

(1) Louver cleaning method 1) Remove the cover (main body) 2) Remove louver 2 3) Remove air separator 4) Clean the inside of the boy. Once cleaning is over, reverse the procedure to refit the cover. Make sure valve C can open and close smoothly, after reassembled louver 1.

Inlet air

Air filter

Regulator

Baffle plateMax.line

Detali of inspection window

Tube Push

Fig. 12-11

Fig. 12-12

Air separator

Cover

Louver 2

E-D0775029-00 58

(14) Adjustment of feeder (14-1) Adjusting method - 1) Turn ON the power on the control box. 2) Turn ON the power switch of feed controller. 3) Check the present frequency by the digital meter (51 Hz at factory shipment). 4) Meet the frequency in case of except above situation. (1) Set amplitude adjusting volume [V] at 50 notch. (2) Position the change over switch at “HAND”. (3) Find out and confirm the frequency at widest vibration from the value of digital meter by turning frequency volume “FREQ” with touching the feeder trough (54~55 Hz). (4) Reduce 4 Hz from the frequency which check at step (3) (At factory shipment : 51 Hz).

Fig. 12-13

Amplitude adjusting Volume [V]

Frequency adjusting Volume (FREQ)

Power Switch

Digit meter

E-D0771045-00 59

(14-2) Adjustment of clearance between magnetic coil and trough mount. 1) Loosen the bolts of magnetic coil fixture base. 2) Insert thickness gauge clearance between magnetic coil and trough mount and set -- clearance at 2.3 mm. 3) Tighten the bolts of magnetic coil base. 4) Confirm the clearance at 2.3 mm.

Fig. 12-14 (14-3) Adjustment of feeder setting position. 1) Check the abnormal nose to contact with feeder if a contacting noise or abnormal - noise comes out from the feeder during the husking. 2) Remove the cover under the feeder. 3) Loosen four bolts of feeder. 4) Adjust the clearance by moving the feeder. Check whether there is no contact point - or any smaller clearance by the above movement. 5) Fix the feeder and cover.

Trough mount Magnetic coil

Hex. Bolt

60

(14-4) Adjustment of feed valve setting position.

1) Remove cover.

2) Loosen the fixing bolts of feed valve.

3) Adjust the position of feed valve so that the feed valve puts the trough as Fig.

4) Fasten the fixing bolts to adjust clearance between both left and right side of feed valve and trough is the same.

5) Fix the cover.

Feed valve

Cover

E-D0771047-00 61

6) Remove cover.

7) Loosen the fixing bolts of feed valve.

8) Adjust the position of feed valve so that the feed valve puts the trough as Fig.

9) Fasten the fixing bolts to adjust clearance between both left and right side of feed valve and trough is the same.

10) Fix the cover.

(15) Adjustment of level sensor

WARNING • Ensure that the main power turned OFF before the inspection

and maintenance work of each part. Confirm the following points if there is any abnormal sensor.

1) Check whether any fixing nuts of a sensor are fastened. • Fix the clearance at 1 mm between the acrylic plate.

2) Check if the distance between a sensor and the acrylic plate is 1 mm. If not, fix it at 1 mm distance.

3) Check if there is no abnormal wiring, such as the break of wiring in a sensor or control box.

• Replace the wiring in case of the break of wiring.

• Fit the wiring if there is the break. Take care of the wiring mistake.

4) Check if the jump wire in sensor is cut. If not, cut it by a nipper.

E-D0775031-00 62

Fig. 12-16 Sensor Fixing Fig. 12-17 Jump Wire

Conduct the sensitivity adjustment, if there is any abnormality at the above points.

(1) Check there is no paddy in the tank.

(2) Turn the sensitivity adjusting volume of sensor counterclockwise until LED lightens on.

(3) Check if LED lightens out when the paddy is fed into the tank. If LED does not lighten out, conduct the procedure from No. (1) again.

Fig. 12-18 Sensor

LED

Sensitivity adjusting volume

Jump Wire

E-D0775032-00 63

(16) Replacement method of tension guide and tension.

CAUTION • Turn OFF the power before the work.

1) Turn OFF the power. Push the emergency switch. 2) Remove the safety cover guide. 3) Remove V-belts. 4) Remove the tension. Make sure the positions of each tension.) 5) Remove the tension guide. Replace the tension and tension guide together. 6) Refit in reverse order after the completion of the replacement. Refer to below figure on the position of the factory shipment.

Fig.12-19 Aspirator Driven Part

Tension

Tension guide

V - Belt Tension

E-D0771050-00 64

13. TROUBLESHOOTING

WARNING • Before maintaining the machine, isolate the machine from the power supply.

• Refit the safety cover after maintenance.

• If the troubles are not remedied even after taking measures following the below instructions, contact your nearby distributor. See the contact address of Satake group companies at the end of this manual.

Conditions of Failure Cause Action to Take

- Insufficient roll pressure. - Adjust the pressure. - Tighten the handle (2) (roll pressure adjustment) to increase the pressure as to set the husking ratio at about 90% without any damage on the grain skin.

- High water content of the paddy. - Measure the water content, and adjust it to a right level.

- Worn rolls. - If the main shaft roll is smaller in diameter than the countershaft roll, exchange the right and left sides. - Replace them with new ones.

- Excessive feed rate. - Decrease the feed rate sing the feed rate adjusting handle.

1. Poor husking ratio.

- Belt slippage. - Tighten the tightener to the level where the belt bends 10-20 mm as pressed with fingers.

2. Unable to increase the feed rate.

- Valve blocked by foreign materials.

- Remove the foreign materials. - Reinstall the piping.

3. Much husk included in the husked rice.

- Maladjusted wind-sorting section. - Belt slippage. - Husking is often interrupted. - Too much feed rate. - Blocked louver.

- Adjust the valve (see the manual). - Tighten the belt. - Use the valve to decrease the feed rate, and avoid any long duration of interruption wherever possible. - Clean the louver.

E-D0771051-00 65

Check list in manual operation. Checklist on Electrical and Air Systems in Manual Operation.

Condition of Failure Cause Action to Take

1. Does not power on (pilot lamp does not illuminate).

- The power switch of the paddy husker control panel is not turned on. - Boken cable. - Brown fuse (F1) on the front of the control box.

- Turn on the switch. - Check the conductance of the power cable. - Replace the fuse (2A).

2. Shutter does not open/close.

- No or insupplicient air feed. - Fault with the air cylinder (for shutter).

- Check valves etc. Ensure the air feed. - Replace the air cylinder.

3. Rolls do no open/ close. - Fault with the air cylinder (for rolls). - Faulty with the speed controller. - Faulty with the regulator. - Excessive tension of the driving hex belt, or wrong belt routing. - Fault with the air valve.

- Replace the air cylinder. - Replace the speed controller. - Replace the regulator. - Adjust the belt tension. Check the belt routing, and reinstall the belt if necessary. - Replace the air valve.

4. Neither shutter nor rolls function

- Fault with the HAND/AUTO change-over switch. - Blow fuse on the panel. - No or insufficient air feed. - Fault with the solenoid valve.

- Replace the switch. - Replace the fuse (2A). - Feed air (0.5 MPa or more). - Replace the solenoid valve.

Fig. 12-1 Fuse position of feeder controller.

Fuse (2A)

Bind Head Screw

E-D0771052-00 66

Check list is Automatic Operation. Checklist on Electrical and Air Systems in Automatic Operation Condition of Failure Cause Action to Take

1. Shutter does not open.

- No Paddy contained in the husker hopper. - The time set on the timer has not elapsed yet from the paddy began to accumulate. - The paddy separator hopper is full. - Fault with the husker hopper lower limit sensor. - Fault with the air cylinder. - Ball valve closed. - Low air pressure

- Supply the paddy. - Wait until the time comes. - Wait until the hopper becomes empty. - Repair the fault. - Replace the sensor. - Replace the air cylinder. - Open the ball valve. - Wait until the air pressure recovers.

2. Shutter does not close.

- Fault with the upper limit sensor of the paddy separator machine hopper. - Low air pressure. - Fault with the air cylinder and solenoid valve.

- Replace the sensor. - Check and adjust the air pressure. - Replace the air cylinder and solenoid valve.

E-D0775033-00 67

14. CONSUMABLE PARTS LIST

If any parts are worn or broken, or when the time has come to replace any consumable parts, contact the nearest sales office.

Model Part No. Part Name Q’ty Condition of Replacement Remark 220110085 Plate 1 Worn out more than 2 mm. 220280440 Plate (side plate) 1 Worn out more than 2 mm. 220300510 Chute 1 Paddy does not flow smoothly. Paddy is flown. 0114021 Felt ring 1 Dust leak

HU

TC110309 Bearing 4 Have Vibration. Main and movable shaft

TD13A047 V – Belt A - 47 1 Worn out, slippage TD13A062 V – Belt A – 62 1 Worn out, slippage. TD13B065 V – Belt B – 65 2 Worn out, slippage. TD13B066 V – Belt B – 66 2 Worn out, slippage. TD13B067 V – Belt B – 67 2 Worn out, slippage. TD13B068 V – Belt B - 68 2 Worn out, slippage. 225131400 Conveyor Screw 1 Cannot distribute even valve is closed.

Husked rice passes only at the center portion. For dividing

T038106 Plate 2 Husked rice cannot discharge. 225131250 Dividing Valve 1 Has no efficient distribution. 225131420 Conveyor Screw 1 Has clogged due to lower capacity of conveyor For mixture 225131410 Conveyor Screw

1 Cannot convey husk that is remained much when seeing trough the inspection window.

For husk

225130540 Screw case 1

No distribution by a big worn hole of screw case.

225130660 Screw case 1 Worn hole of screw case. 225130670 Screw case 1 Worn hole of screw case. 225131610 Tension 2 Tension is much loose. 225133620 Husked rice side

HA

225133630 Tension guide 1 Tension is much loose.

Husk side

E-D0371039-00 68

EMERGENCY ADDRESS AND TELEPHONE

Produced By SATAKE (THAILAND) CO.,LTD. 133 Moo 5 Bangkadi Industrial Park Tivanon Road Pathumthani 12000 Thailand Tel. 66-2-501-1180 Fax. 66-2-501-1188 E-Mail: eng-sth@sataketh.com Home Page : www.sataketh.com Sold By SATAKE CORPORATION 2-30 Saijo Nishihonmachi Higashi-Hiroshima-Shi Hiroshima 739-8602 Japan Tel. 81-824-20-8539 Fax. 81-824-20-0865 E-Mail: kg-hiroshima@satake-japan.co.jp

E-D0371040-00 69

SATAKE (THAILAND) CO., LTD. 133 Moo 5 Bangkadi Industrial Park Tivanon Road Pathumthani 1200 Thailand Tel. 66-2-501-1180 Fax. 66-2-501-1188 E-Mail: eng-sth@sataketh.com Home Page : www.sataketh.com